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Information injection-pump assembly
ZEXEL
101603-9920
1016039920
Cross reference number
ZEXEL
101603-9920
1016039920
Zexel num
Bosch num
Firm num
Name
101603-9920
DPICO
INJECTION-PUMP ASSEMBLY
6D16 * Q
6D16 * Q
Calibration Data:
Adjustment conditions
Test oil
1404 Test oil ISO4113 or {SAEJ967d}
1404 Test oil ISO4113 or {SAEJ967d}
Test oil temperature
degC
40
40
45
Nozzle and nozzle holder
105780-8140
Bosch type code
EF8511/9A
Nozzle
105780-0000
Bosch type code
DN12SD12T
Nozzle holder
105780-2080
Bosch type code
EF8511/9
Opening pressure
MPa
17.2
Opening pressure
kgf/cm2
175
Injection pipe
Outer diameter - inner diameter - length (mm) mm 6-2-600
Outer diameter - inner diameter - length (mm) mm 6-2-600
Overflow valve
131424-5520
Overflow valve opening pressure
kPa
255
221
289
Overflow valve opening pressure
kgf/cm2
2.6
2.25
2.95
Tester oil delivery pressure
kPa
157
157
157
Tester oil delivery pressure
kgf/cm2
1.6
1.6
1.6
Direction of rotation (viewed from drive side)
Left L
Left L
Injection timing adjustment
Direction of rotation (viewed from drive side)
Left L
Left L
Injection order
1-5-3-6-
2-4
Pre-stroke
mm
3.3
3.25
3.35
Beginning of injection position
Governor side NO.1
Governor side NO.1
Difference between angles 1
Cal 1-5 deg. 60 59.5 60.5
Cal 1-5 deg. 60 59.5 60.5
Difference between angles 2
Cal 1-3 deg. 120 119.5 120.5
Cal 1-3 deg. 120 119.5 120.5
Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5
Cal 1-6 deg. 180 179.5 180.5
Difference between angles 4
Cyl.1-2 deg. 240 239.5 240.5
Cyl.1-2 deg. 240 239.5 240.5
Difference between angles 5
Cal 1-4 deg. 300 299.5 300.5
Cal 1-4 deg. 300 299.5 300.5
Injection quantity adjustment
Adjusting point
-
Rack position
11.3
Pump speed
r/min
800
800
800
Each cylinder's injection qty
mm3/st.
59.8
58.3
61.3
Basic
*
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_02
Adjusting point
D
Rack position
8.7+-0.5
Pump speed
r/min
500
500
500
Each cylinder's injection qty
mm3/st.
7.6
6.5
8.7
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(11.3)
Pump speed
r/min
800
800
800
Average injection quantity
mm3/st.
59.8
58.8
60.8
Basic
*
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1+0.3
Pump speed
r/min
1375
1375
1375
Average injection quantity
mm3/st.
77.2
73.2
81.2
Fixing the lever
*
Injection quantity adjustment_05
Adjusting point
C
Rack position
R1+0.1
Pump speed
r/min
600
600
600
Average injection quantity
mm3/st.
48.5
44.5
52.5
Fixing the lever
*
Injection quantity adjustment_06
Adjusting point
I
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
73
63
83
Fixing the lever
*
Rack limit
*
Injection quantity adjustment_07
Adjusting point
H
Rack position
9.5+-0.5
Pump speed
r/min
275
275
275
Each cylinder's injection qty
mm3/st.
8.7
7.4
10
Fixing the rack
*
Remarks
(check)
(check)
Timer adjustment
Pump speed
r/min
1250--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
1200
Advance angle
deg.
0.8
Timer adjustment_03
Pump speed
r/min
1375
Remarks
Measure the actual advance angle.
Measure the actual advance angle.
Timer adjustment_04
Pump speed
r/min
-
Advance angle
deg.
5
5
5
Remarks
Speed, measure actual advance, end of effect
Speed, measure actual advance, end of effect
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Torque cam stamping: T1
(2)Tolerance for racks not indicated: +-0.05mm.
(3)RACK LIMIT
----------
T1=G42
----------
----------
T1=G42
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Use the hole at R = aa
(2)Stopper bolt set position 'H'
----------
aa=35mm
----------
a=33deg+-5deg b=(38deg)+-3deg
----------
aa=35mm
----------
a=33deg+-5deg b=(38deg)+-3deg
Stop lever angle
N:Engine manufacturer's normal use
S:Stop the pump.
(1)Free (at delivery)
(2)Rack position = approximately aa.
(3)Set the stopper bolt at speed = bb and rack position = cc (non-injection rack position). Confirm non-injection.
(4)After setting the stopper bolt, confirm non-injection at speed dd. Rack position = ee (non-injection rack position)
----------
aa=17.4mm bb=1375r/min cc=6.7-0.5mm dd=275r/min ee=(8.3)mm
----------
a=17deg+-5deg b=(27deg) c=2deg+-5deg
----------
aa=17.4mm bb=1375r/min cc=6.7-0.5mm dd=275r/min ee=(8.3)mm
----------
a=17deg+-5deg b=(27deg) c=2deg+-5deg
0000001501 MICRO SWITCH
Adjustment of the micro-switch
Adjust the bolt to obtain the following lever position when the micro-switch is ON.
(1)Speed N1
(2)Rack position Ra
----------
N1=400r/min Ra=9.2+-0.1mm
----------
----------
N1=400r/min Ra=9.2+-0.1mm
----------
Timing setting
(1)Pump vertical direction
(2)Position of timer's tooth at No 1 cylinder's beginning of injection
(3)B.T.D.C.: aa
(4)-
----------
aa=16deg
----------
a=(1deg)
----------
aa=16deg
----------
a=(1deg)
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Dpico
Nissan-Diesel
Dpico
101603-9920
INJECTION-PUMP ASSEMBLY
6D16
6D16